A friction stir welding equipment with high rotation speed and constant load is successfully developed in this study to weld the multi-laminated silicon steel sheets widely used on regular transformers. This equipment consists of a spinning unit, a loading unit, and a feeding unit. A WC round rod with 3 mm diameter is used as welding tool. Under different operating conditions, such as the normal load(140~480 N), the spindle speed (12000~24000rpm), the feeding rate (0~1.58 mm/s), the welding characteristics and the welding mechanism of multi-laminated silicon steel sheets, and the welding feasibility of the transformer are investigated. Firstly, the contour map of welding depth in terms of spindle speed,normal load, and depth of point welding is established for dwell welding time 15 seconds. Secondly, based on this contour map, two experimental conditions of the long-pass welding tests are selected to investigate the effect of normal load (Fd), the spindle speed (Ns), and the feeding rate (f) on the failure load of weld under the shear. According to the experimental results, the empirical formula is obtained as Ff =40.6(Fd¡DNs)1.123(f)-0.791. In this formula,(Fd¡DNs)1.123(f)-0.791 is proportional to the frictional work per unit moving distance. With the larger frictional work, this represents the heat generation of the workpiece material is higher with more uniform friction stir, so that the bonding strength of the material increases and the failure load of weld is larger. According to the micrograph observations, the thermo-mechanically affected zone is significantly influenced by high heat action generated from the friction between the tool and the weld surface region, so that the plastic flow of the workpiece material occurs to cause the multi-laminated silicon steel sheets bonding together. Finally, the transformer is successfully welded under the experimental conditions of the long-pass welding tests with the smaller welding depth and the better failure load.

Bolted cores made of coated silicon steel sheets constitute a vital part of heavy electrical equipment for transformers, motors and turbogenerators. Bolted laminates are eminently suitable for facilitating smooth magnetic flux paths, but, unfortunately, they are unable to suppress interlaminate shearing caused by flexural vibration generating noise levels often exceeding 100 dB during operation. The resulting din and cacophony in the surrounding has become a major environmental concern. This thesis makes an attempt to develop theoretical, experimental and numerical models for evolving an effective stiffness approach enhancing the design and analysis underlying nonlinear flexure of bolted laminates. While large machine cores contain thousands of thin sheets bolted together along with end plates, this thesis reports the results obtained on two different assemblies. Two 375 mm long 60 mm wide and 10 mm thick plates assembled with 3, 4 or 5 bolts constitute the first configuration. The second one which is much more realistic comprises 80 coated 270 micron silicon steel sheets with end plates of 2 or 4 mm thickness held together by 3 or 5 bolts. Static 3 point bend tests on these bolted assemblies are followed by instrumented impact tests. Static bending tests highlight the role of frictional nonlinearity inducing a drop in the stiffness due to sliding between the plates. An experimentally determined effective modulus in the initial linear range is utilized for static and dynamic finite element simulations. Nonlinear response of bolted plates is simulated using contact elements in between the sliding plates, plates and the bolts heads. Since the first fundamental mode of vibration dominates the tribomechanical vibration induced noise, the primary focus is on the fundamental frequency in bending. There is generally a good overall agreement in all the results obtained through theory, experiment and FE simulation. Experiments, however, unveil quite complex nonlinear effects induced by friction and plasticity outside the scope of this thesis. However, the low amplitude response of bolted laminates which is reasonably well captured in this thesis represents the starting point for initiating a more elaborate effort for addressing large amplitude nonlinear flexure in bolted laminates. These findings shed light on estimating and controlling noise and vibration levels in heavy electric machines.